Annual Review July
TWI
Mission To create value and enhance quality of life for Members and stakeholders through engineering, materials and joining technologies. Values What we believe in
... and how we behave
Technology reputation and innovation Member and customer focus Ambition and flexibility
Creativity, dedication and continued learning Professional excellence, integrity and independence Motivation, teamwork, respect and discipline
Vision To enhance our international technology reputation in diversified sectors leading to growth in market share. Direction To accelerate the generation of member benefits by:
Cover photo Daniel Davies Resonance testing
Increased rate of innovation and creative problem solving Focus on provision of world-class technology Synergy between technology development, knowledge transfer and certification Customer service excellence
TWI Governance
A mission to generate benefits for our Members and their businesses and flexible responses to the signals of our markets.
The Bevan Braithwaite Building
Council
Council is the governing body of TWI and it consists of elected representatives from Industrial Member Companies and Professional Members.
President John Baxter FRSE, FREng, FWeldI BP Nazmi Adams Jonathan Beasley Dr Debashish Bhattacharjee Dr David Clarke Eur Ing Norman Cooper CEng, FIMMM, FWeldI Dr Richard Dolby OBE, HonDMet, FREng, FIMMM, HonFWeldI Maxwell George CEng, FWeldI Eur Ing David Howarth CEng, MIMMM, FWeldI Professor John Irven Professor Richard Jones Dr Steven Jones CEng, FWeldI Eur Ing Paul Jordinson CEng, FWeldI Nigel Knee Eur Ing Mike Lawrence CEng, MIMMM, MWeldI Eur Ing Crawford Lochhead, CEng, FIMMM Eur Ing John Marlow MSc, CEng, FWeldI Allan Middleton Dr Stephen Paterson PhD, CEng, MIMMM, SenMWeldI Dr Robert Rivett Dr Krishnan Sankaran Eur Ing David Smith CEng, MIMMM, FWeldI Julio Tolaini CEng, SenMWeldI Paul Tooms John Waud CEng, MIMMM, FIQA
Chairman Steven Yianni MA(Cantab), MBA, CEng, FIMechE Network Rail
Vice Chairman Grahame Nix OBE Consultant
ESAB Group (UK) Ltd GKN plc Tata Research, Development & Technology E.ON New Build & Technology BAE Systems Marine Ltd Professional Members Professional Members Professional Members Consultant DSTL Professional Members Professional Members EDF Energy Nuclear Generation Ltd Professional Members Professional Members Professional Members J Ray McDermott Middle East Inc Shell UK Ltd Emerson Electric - Europe The Boeing Company Professional Members Professional Members BP Exploration & Production Technology Group Professional Members
Finance and General Purposes Committee Chairman Steven Yianni MA(Cantab), MBA, CEng, FIMechE Vice Chairman Grahame Nix OBE Members Eur Ing Norman Cooper CEng, FIMMM, FWeldI Eur Ing David Howarth CEng, MIMMM, FWeldI Professor John Irven „ 5
Message from the Chief Executive
2011 was a very busy and successful year for TWI exceeding the record years of 2009 and 2010. Key highlights for 2011 included: Group turnover increased to £61m and profit before depreciation again exceeded £7m. Contract order intake exceeded £27m, strengthening the order book to nine months. Industrial membership, contract R&D, training and professional programmes income all exceeded targets with annual growth of over 15% compared with last year. Staff numbers now exceed 700 with strong growth particularly in our international subsidiaries, the total turnover of which grew to £13m, an increase of 34%. Plant Integrity had an excellent year with the successful launch of the latest version of the Teletest equipment which has been very well received by the market, leading to significant profitable growth.
Looking towards 2012, our long-term contract order book is very positive, but there are also significant uncertainties in national and international economic forecasts. Whilst TWI has been very successful at managing progress through recent years, the 2012-14 Corporate Plan is one of consolidation in the UK, but with significant growth opportunities being pursued overseas. For TWI to continue to progress towards our long-term vision, the guiding principle must remain: A deep-seated sense of our mission to generate benefits to our Members and their businesses and a positive and flexible response to the signals from our markets to adapt our operations accordingly. Our continued improvement has been ensured by the efforts and dedication of TWI staff and the advice and support of our Council and Boards. I would like to extend my sincere gratitude to everyone involved.
Christoph Wiesner Chief Executive
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ExecutiveBoard Board Executive
2011 was a very busy and successful year for TWI exceeding the record years of 2009 and 2010.
Reza Razmjoo BSc, MSc, PhD Director, Business Development
Gillian Leech FAIA, MBCS Director, Finance and Services
Keith White ACA Associate Director
Paul Craddock BSc, MSc, CEng, MIMMM, FWeldI Non-executive Director
Bertil Pekkari HonFWeldI Non-executive Director
Christoph Wiesner Dipl-Ing, Dr és sci tech, FREng, FIMMM, FWeldI Chief Executive
Professor Aamir Khalid BSc, MSc, PhD, MBA Director, Technology
Rob Scudamore BSc, MSc(Eng), PhD Associate Director
Paul Woollin MA, PhD, CEng, SenMWeldI Director, Research
Eur Ing Chris Eady BSc(Hons), MSc, CEng, MRAeS, FWeldI Associate Director, Professional Affairs and Certification
Keith White ACA
Associate Directors Eur Ing Tim Jessop BSc(Eng), ACGI, CEng, FWeldI; Iain Smith BSc, MSc, CPhys, CEng, MInstP, MWeldI; Graham Wylde BSc, PhD, CEng, MIMechE, SenMWeldI; Roger Wise BSc, PhD, CPhys, CEng; Sue Dunkerton BSc, CEng, FIMMM, FWeldI; Professor Eur Ing Sayee Raghunathan BTech, MBA, CEng, FIMMM, FCQI, FWeldI, FEI, FIET; Peter Oakley BSc, MBA,
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Gillian Leech Director, Finance and Services
Carne Wilsher Orbital TIG welding
70 60
Group Income by Product
£m
50
So ware, Licencing, Projects + Others
40
Training, Examina ons + Professional
30
Consul ng + Engineering Services
20
Contract R+D
10 0 2005
2006
2007
2008
2009
2010
2011
2012 (Budget)
18,000 16,000
£'000's
14,000 12,000
Training & Professional Income
10,000 8,000 6,000 4,000 2,000 0
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2005
2006
2007
2008
2009
2010
2011
2012 (Budget)
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Business Overview
Group turnover increased to around £61m and profit before depreciation again exceeded £7m.
£2.9m
Asset acquisition over the last five years
£6.7m
£7.7m
Land & Buildings
Plant & Equipment
Proj/Gift Plant & Equip
700 600
Group Staff Numbers
500 400 300 200 100 0 2005
2006
2007
2008
2009
2010
2011 2012 (Budget)
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Reza Razmjoo Director, Business Development
Emilie Soileux and Carol Johnston Examination of a fatigue specimen
Council Professional Board
Certification Management Board
Research Board
TWI Certification Ltd
Remuneration Committee
Finance and General Purposes Committee
Audit Committee
Executive Board
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
TWI Structure
We have implemented our global market strategy and new offices in North America, India and Central Asia will enable us to serve our local Members better.
TWI Group Companies The Welding Institute (holding company) TWI Ltd (trading as) TWI Ltd TWI Technology Centre (North East) TWI Technology Centre (Yorkshire) TWI Technology Centre (Wales) TWI Aberdeen TWI Australia TWI China TWI Thailand TWI Turkey
TWI Pakistan TWI India TWI Certification Ltd TWI Gulf TWI Middle East TWI North America TWI Services (SEA) TWI Technology (S E Asia) The Test House Ltd Plant Integrity Ltd Granta Park Estates Ltd
Services Membership Consultancy and Project Support Training and Qualification Intellectual Property and Licensing Contract R&D Technology Transfer Software Innovation
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TWI and Granta Park
In 2010 TWI became the debt-free owner of the eastern half of Granta Park which includes the original TWI site, the Riverside development and additional development land. To make the most of such property assets and finalise TWI’s headquarter developments at Granta Park for the long term, further initiatives are under consideration. Eric Parry Architects, the award-winning London practice, responsible for the original Granta Park layout, was commissioned to carry out a review of the TWI site and make conceptual proposals. The outline proposal involves a general westward shift of TWI’s operation into an enlarged Bevan Braithwaite Building; the demolition of ageing and expensive-tomaintain buildings and provision of new technology, conferencing, catering and educational spaces and new road layouts. The development will increase our operational space to accommodate growth, address inefficiencies arising from ageing buildings and foster better cross-group co-operation by integration of the current fragmented building arrangements. The design allows the continued operation of existing buildings whilst new facilities are being constructed; a phasing of the work in line with financial and business environment circumstances and includes potential to unlock further tenant space to add to TWI’s future endowment. Ultimately, the aim is to create a well-ordered and flexible TWI campus in harmony with existing Granta Park space, the surrounding landscape and the Abington villages.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Staff Profiles Jon Blackburn
Marcio Milititsky
I came to TWI in 2006 as an Engineering Doctorate Research Engineer. Performing my research in an industrial facility helped me to understand the commercial environment in which TWI operates. After completing my Doctorate, I became a Project Leader working with clients in different industry sectors across the world. In 2011, I was promoted to Manager of the Laser and Sheet Processes Section, allowing me to apply and develop skills gained through completion of a Postgraduate Diploma in Management Sciences from Manchester Business School. I am fortunate that TWI have given me this opportunity and are providing the necessary training and mentoring for me to progress in this role.
Being a metallurgist, I was thrilled to join TWI in 2008 as an engineer in the Metallurgy, Corrosion and Surfacing Department with the opportunity to carry out failure analysis and engineering projects. With a background in the automotive industry implementing new materials and stainless steels, coming to TWI was a logical move to widen my knowledge and skills. Since 2010 I have been managing the stainless steel and non-ferrous alloys and characterisation section, a promotion made possible because of the support I received from management and colleagues. The technical challenges we face every day keep the work interesting and the opportunity to develop in a managerial role has been an exciting development. I am very grateful to TWI for giving me the opportunity and look forward to the future.
Sarah McCarthy
David Seaman
I joined TWI’s Technology Transfer department in 2001 managing projects and major work packages for TWI’s UK regional initiatives and was able to progress to a Senior Project Leader role. In January 2011 I transferred to the Industrial Member Services department, continuing to deliver technology transfer projects as well as being involved in implementing the new initiative on customer satisfaction and I look forward to helping TWI achieve customer service excellence across the business. I am lucky to have worked with some great people at TWI which has given me the opportunity to grow both personally and professionally.
I joined TWI in 2000 as a Trainee Technician in the Fracture Laboratory and became involved in a variety of mechanical testing techniques on differing materials to relevant standards. Between 2000-2005 I attained first an ONC and then an HNC in Mechanical Engineering at West Suffolk College. After a very enjoyable 11 year tenure in the Fracture Laboratory, I was recently promoted to the position of Team Leader in the H2S Laboratory. I feel very fortunate to have been given the opportunity to develop my career at TWI and am very excited about the future.
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Corporate Social Responsibility Corporate social behaviour connects TWI with employees, their families and friends and the wider community. The support of educational activities based around engineering, science and technology adds to the social framework. People TWI recognises that business success depends on a capable and motivated workforce. It understands the importance employees place on achieving a good work/life balance so has introduced a flexible hours scheme giving staff more control over their working day. The company is committed to providing learning and development opportunities delivering over 40 courses annually, tailored to support the growth and development of staff. TWI has employees completing qualifications ranging from apprenticeships to doctorates. Initiatives are in place to develop effective performance management processes by using a competency framework. In 2011 a third of vacancies were filled by internal candidates and technical staff are encouraged to hold membership of a relevant professional institute. TWI offers student placement opportunities and collaborates with universities to share its expertise and provide an insight into working at TWI. Several of these students return to become permanent employees. Emma Smith Craig Carter and Kerry Jamieson
Environment TWI’s certified quality management systems cover all UK offices and its software. The certified Environmental Management System now covers three UK offices. TWI made a commitment through its environmental management system to collate and report on its greenhouse gas (GHG) emissions from 2010 and intends to use this data as its baseline the future. Almost 90% of TWI’s GHG emissions come from electricity and gas usage plus air transport. TWI continues to reduce its GHG by recycling a greater percentage of waste, increasing insulation of buildings and investigating renewable energy to gradually reduce its dependence on electricity and gas. Granta Park
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Safety Our drive to continually improve safety performance is led from the top and Board responsibility for Quality, Environment and Health and Safety rests with the Chief Executive. TWI’s Health and Safety Management System has also been externally certificated and currently covers two UK offices. Despite the continuing growth of the company, TWI had just one lost-time accident in 2011. An extensive programme of training ensures staff have the necessary knowledge and skills to perform the wide variety of tasks required in a safe and competent manner. TWI’s health and safety objectives include an improved risk assessment management system and the setting up of a Help Desk for staff use.
Mark Caswell and Ian Few
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Corporate Social Responsibility Community TWI funds the educational outreach activities of The Welding Institute which take the form of visits by schools, colleges, universities, teachers, parents and the wider community. This showcases the careers, skills, developments and research within the world of welding, joining and allied technologies and for this programme alone over 700 visitors were welcomed to TWI. Local as well as national charities received donations from TWI from the money saved by sending out its company Christmas cards electronically. The choice of charities was decided by suggestions from the staff. In addition, local primary and secondary schools, sports clubs and charitable initiatives are supported by financial donations and voluntary work undertaken by TWI staff. Welding Careers Open Day
Welding with Chocolate
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Research and Development Activities
Iain Whatmore pH measurement
Research Board
Last year was the second year of the 2010-2012 Core Research Programme. TWI worked on 58 projects, covering materials performance, structural integrity, non-destructive inspection, welding and surface engineering technologies, with output monitored by the three Research Board Committees. Chairman Professor John Irven
Consultant
Chairman, Engineering, Metals and Weldability Committee Professor Bob Ainsworth University of Manchester Chairman, Plastics, Adhesives and Electronics Committee Professor Paul Curtis DSTL Porton Down Chairman, Joining and Fabrication Committee Dr David Widgery Consultant Members Natalia Becerra Dr Steve Beech Professor Harry Bhadeshia Geoff Dunn Dr Bill Glass Evelyne Guyot Peter Hilton Samuli Heikkinen Karen Huber Dr Tim Hurd Dr Ammer Jadoon Professor John Knott Ricky Martin Professor Jagath Mawella Dr Luis Meniconi Ernst Miklos Olivier Moog Dr David Panni Dr Adam Pitman Brian Robb Professor Jack Samuelsson Harry Swan Dr Christopher Thornton Jitesh Vaja Dr Declan Weldon
Rolls-Royce plc Rolls-Royce plc University of Cambridge ExxonMobil Development Company AREVA NP AREVA NP Shell UK Ltd F4E Caterpillar Inc Corus Research and Development BP Exploration University of Birmingham The Boeing Company Ministry of Defence PETROBRAS Linde Group Techlam SA J C Bamford Excavators Ltd Airbus UK Rolls-Royce plc Volvo AB Thomas Swan and Co Ltd BP Exploration AWE plc Air Products & Chemicals Inc
Professor John Irven
Professor Bob Ainsworth
Professor Paul Curtis
Dr David Widgery
Research Board is a committee of representatives from TWI Member companies. It determines the content and guides the progress of the Core Research Programme which underpins the services provided to the Industrial Membership.
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Cold spray deposition of metal matrix composites „
Dense, oxide-free coating of B4C particles in an aluminium matrix
Following the integration of a second powder feeder hopper with its cold spray system, TWI can now co-deposit metallic materials and hard ceramic particles (eg B4C, Al2O3 and SiC) in a dense coating. The advantage of cold spray deposition is that it does not melt the deposited material and so can be used to incorporate thermally sensitive materials into metallic matrices. The proportion of each phase can also be adjusted through the coating thickness to form functionally graded coatings for a wide variety of applications. For example, Al-B4C deposits up to several tens of millimetres thick and with bond strengths of ≈24 MPa have been deposited for potential use in neutron shielding applications
Real-time full matrix capture for ultrasonic NDT Full matrix capture (FMC) is a fairly recently developed NDT inspection technique, using several phased array probes on a single component and captures the complete time domain signal from every element. Research at TWI has built on existing focusing algorithms and developed them for use with FMC. This allows for data acquisition and post-processing rates of over 100 frames per second; significantly faster than any known existing implementation, made possible through parallel post processing of data over a graphics card. Detection and characterisation of artificial flaws using the FMC technique
Weld flaw tolerance in pipelines subjected to plastic strain during reeling During offshore pipelay operations, the pipe may be subjected to high strains in excess of 3%. Conventional methodologies for setting weld flaw tolerance levels are not ideal for such high strain cases. Improved analytical techniques, using a strain based failure assessment diagram, have consequently been developed for assessing pipelay conditions. A specialist test facility was built to simulate pipelay conditions and used to validate the proposed approach. It can apply axial loads corresponding to yield magnitude in the pipe wall whilst simultaneously applying an internal pressure of up to 1000 bar. Simulating pipelay conditions in a tensile load frame.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
2011 Technical Achievements
Micro/nanometre-scale welding of polymers using Clearweld Using the Clearweld technology invented and developed at TWI, an advance has enabled laser welds in polymers at the micro-scale and, potentially, at the nanoscale. Lithographic technology used in the electronics industry has been harnessed to permit Clearweld dye deposition at the nano-scale. Key features include high definition of welds at the edges of precisely manufactured features in components to be welded. Applications include microfluidics for medical diagnostics.
Micrometre-scale welds in polymeric substrates
Hybrid laser-MIG welding of aluminium alloy butt joints with adaptive control TWI has developed procedures for fit-up sensitive, real-time control of hybrid laserMIG butt welding to extend gap tolerance to at least 10-13% of plate thickness compared with <5% when welding autogenously. The work used hybrid fibre laser-MIG welding with adaptive control, using a seam-tracking sensor-driven control system mounted ahead of the welding process. This allowed response in real time, to variations in joint fit-up. As a test case, butt welds were made in 4mm thickness alloy 5083 plate. It is believed this is the first time adaptive control has been demonstrated for hybrid laser-MIG welding of aluminium alloys. Laboratory set-up used for adaptive control of hybrid laser-MIG welding
Learning from recent nuclear construction projects
Nuclear new build
In 2009, a UK steering group was formed under the ‘Engineering the Future’ organisation, to initiate a project funded by the Office for Nuclear Development (OND) and the Institution of Civil Engineers, to learn from recent civil nuclear construction projects. Interviews were conducted with key personnel around the world, to identify and understand those issues that have potential to significantly impact the construction of new nuclear plant. In 2011, the steering group set up three working groups to produce guidance on best practice in the areas of concrete quality, nuclear quality & safety culture and welding. TWI participated in the steering group and chaired the welding working group, which made a set of recommendations so that welding on new nuclear stations will be of the requisite quality.
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Paul Woollin, Director, Research Aamir Khalid, Director, Technology
James Bell and Noshad Mohsemi Hot wire TIG welding
Core Research Programme The Core Research Programme value was around £2.7m including leverage from public funding and sponsoring and supervising Industrial Case Award and Engineering Doctorate students. Thirty-five TWI Research Reports were discussed and 34 were approved during Research Board meetings and have been issued to Members or placed onto TWI’s corporate website.
safety and reliability of welded structures and nine dealt with the development of novel or improved joining and surfacing technology. Projects started in 2011 include the following:
As of January 2012 there are a total of 33 Research Associates, located at partner universities and at TWI and its regional centres. These comprise 14 Engineering or Industrial Doctorates, 18 PhDs (including five studying through TWI’s agreement with the newly formed Brunel Innovation Centre, located in Abington Hall) and one short-term internship. TWI remains very active in supporting Members’ interests in national and international standards committees (AFCEN, API, AWS, BSI, CEN, IIW, ISO and NACE). Recent emphasis has been on the revision of BS 7910 and developing TWI’s contribution to the AFCEN French nuclear standards.
Validation of an acceptance criterion for avoidance of hydrogen embrittlement of subsea dissimilar joints. Toughness requirements for steel for arctic and low temperature environments. Optimisation of weld overlay for productivity and corrosion resistance. Improving the integrity management process for bonded hoses. Friction stir welding of steels.
TWI was involved in 80 collaborative projects in 2011 with a further 25 approved and in contract negotiation at the end of the year and 30 in various stages of the submission/appraisal process. Collaborative projects provided 21% of TWI’s income in 2011. Seventy four projects were part-funded by the European Commission and 16 by UK government (Technology Strategy Board).
Contract R&D TWI’s Group Sponsored Project (GSP) portfolio comprised 26 projects in 2011, with a further 15 in various stages of launch at the end of the year. GSPs provided 4.3% of TWI’s income. Of the existing projects, 17 were conducted with the aim of improving
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Research and Development Activities
The Core Research Programme is a unique advantage of Industrial Membership, investing half the membership fees into research to develop cutting edge capabilities and world-class expertise for our Members’ future needs.
Major collaborative research projects include: MERLIN: Development of aero engine component manufacture using laser additive manufacturing. SAFEFLAME: Development of oxy-hydrogen flame for welding, cutting and brazing. POLY-SOLVE: Development of a selective, green, solventbased recovery process for waste polystyrene and polycarbonate. MU-TOOL: Novel tooling for composites curing under microwave heating. SMARTDRESS: Adaptive tip dress control for automated resistance spot welding. DASHWIN: Development of advanced shearography system for on-site inspection of wind turbine blades.
Innovation TWI has a long track record of inventions that ultimately have significant industrial impact. Investment in ideas generation and development is provided via exploratory projects, funded by licence royalties from inventions, which exceeded £1.65m in 2011. Once an invention is considered worthy of protection, a formal stage-gate process is used to ensure structured industrial exploitation of the intellectual property. Five distinct inventions are currently going through the process and 23 patent applications are being pursued. TWI currently has 201 granted patents and offers licences in friction stir welding, reduced pressure electron beam welding, Surfi-Sculpt electron beam surface texturing, Vitolane coatings and CrackFirst fatigue sensors.
Facilities Significant investment has been made to increase environmental testing capability, including doubling the size of the H2S laboratory, two additions to the suite of sour service, servohydraulic crack growth rate machines supporting on-going testing of girth welded steel catenary risers for deepwater applications and an additional gas chromatograph and associated autoclaves for characterising permeation through, and degradation of, polymers in oil and gas service.
TWI was involved in 80 collaborative projects with a value of tens of millions of pounds.
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Colin Walters Manager, Industrial Member Services
Technology Awareness Day
Industrial Membership One hundred and eleven organisations became Industrial Members of TWI in 2011, providing an additional annual income of £1m. Members’ satisfaction with the quality of TWI services has meant that despite the continuing global recession the rate of resignations was maintained well below that of recruitment. As a result, overall Membership grew to 692 by the end of the year providing a total annual income of almost £8m. The Members represent over 2000 organisations operating in some 4500 locations worldwide.
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Growth targets were exceeded in all industry sectors with the exception of oil and gas for which some recruitment activities had to be curtailed due to unrest in Libya and neighbouring countries. Half of all new Members are based outside the UK, further enhancing the global presence of TWI. New Members were recruited in 23 countries with growth particularly strong in the USA where TWI now has 59 Members. Main TWI Groups The TWI Groups serving Industrial Members and customers and their managers are listed below.
Advanced Materials and Processes (Cambridge and Middlesbrough)
Roger Wise
Electron Beam, Friction & Forge and Laser & Sheet Processes (Cambridge, South Yorkshire and Middlesbrough)
Rob Scudamore
Industrial Member Services
Colin Walters
Manufacturing Support (Cambridge and Middlesbrough)
Sayee Raghunathan
Metallurgy, Corrosion and Surfacing (Cambridge and South Yorkshire)
Steve Shi
Non-destructive Testing
Tat-Hean Gan
Structural Integrity
Geoff Booth
Training and Examinations (United Kingdom, South East Asia, Middle East, Central Asia, India)
Tom Setterfield, Ernie Moskini, Brian Hunt, Farshid Alizadeh, Jim Kerins
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Industrial Membership
One hundred and eleven organisations from 23 countries joined TWI in 2011.
The Technology groups link with the Product, Industry Sector and Marketing and Promotion teams responsible for co-ordinating business development. This technology/sales product matrix is supported by the teams in Business Systems and IT, Contracts, Purchasing, Finance, HR, Quality, Health, Safety and Environment, and Site Services.
TWI supports over 2000 organisations in 4500 locations throughout the world.
Aerospace
Richard Freeman
Collaborative R&D Projects
Paul Sherrett
Construction, Engineering and Automotive
John Davenport
Electronics, Photonics, Sensors and Nanotechnology
Norman Stockham
Equipment, Consumables and Materials
Chris Wiseman
Engineering Site Services
Ian Daniel
Group Sponsored Projects
Adrian Duncan
Key Account Management
Richard Freeman
Marketing and Promotion
Colin Walters
Medical
Terry Oâ&#x20AC;&#x2122;Neill
National and European Manufacturing and Health Technology Networks
Sue Dunkerton
Oil, Gas and Chemical
Amir Bahrami
Power and Energy Knowledge Transfer Network
Sayee Raghunathan
Single Client Projects
Peter Oakley
UK Programmes
Ian Norris
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James Bell Submerged arc welding
Technologies
Geoff Booth Manager, Structural Integrity
Jerry Godden Inspection of failed crack arrest plate
Achievements in 2011
Full scale resonance testing of pipes up to 970mm diameter. Guidelines for the fatigue assessment of pipe girth welds subjected to low stresses in the spectrum. Accurate modelling of residual stresses in multi-pass pipe girth welds. Development of R-curves for low restraint conditions. Improved procedures for weld assessment for sour conditions and for high strain. Extension of guided wave inspection of pipes beyond bends and branches.
Plans for 2012
Automation of collapse load and stress intensity factor calculations for pipeline girth welds. Corrosion fatigue of mooring chains in seawater. Inspection and testing of decommissioned offshore structures. Publication of a new version of BS 7910, the industry standard for weld flaw acceptance assessment. Release of CRACKWISE 5 to reflect the new version of BS 7910.
Industry standard for weld flaw acceptance assessment.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Structural Integrity
Our highly committed staff continue to provide realistic solutions to technically demanding client projects.
Case Study A project was carried out for an Industrial Member on a box girder bridge built in 1954 with an 18mm thickness orthotropic steel deck and 10mm thickness transverse girders. Eight millimetre long fillet welds formed their connections to the deck and were known to contain root flaws (heel cracks) which originated during fabrication. These cracks had been subject to periodic non-destructive examination since construction. TWI was approached to conduct a fatigue and fracture assessment on the degree of risk that these flaws could initiate a failure in the deck plate. After reviewing existing records a programme of strain gauge measurement, finite element analysis (FEA) and non-destructive evaluation records analysis, fatigue and fracture mechanics calculations were devised and recommended. The fatigue and fracture assessments followed the methodology in BS 7910, an accepted guide to the application of fracture mechanics for the assessment of flaws in steel. Two levels of fracture refinement were adopted, one using the standard stress intensity factor solutions from BS 7910 (conservative), the other involving TWIâ&#x20AC;&#x2122;s FEA of the actual joint and flaw geometry in the bridge (representative). Both results indicated that the risk of failure by fatigue and/or fracture was low.
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Tat-Hean Gan Manager, Non-destructive Testing
Angelique Raude Eddy current array inspection of pipe
Achievements in 2011
Development of a real-time condition monitoring system for wind turbine rotating components. Autonomous robot for the automated inspection of nozzle welds in nuclear reactors. Tomographic inspection of storage tank floors using ultrasonic guided waves. Real-time full matrix capture for ultrasonic non-destructive testing with acceleration of post-processing through graphic hardware. Advanced phased array inspection of offshore mooring chain.
Plans for 2012
Development of pulsed eddy current system for inspection of corrosion under insulation. Development of an advanced medium range ultrasonic technique using guided waves. Ultrasonic detection and characterisation of stress corrosion cracking in weld overlay cladding. The use of non-linear ultrasonic techniques for the detection of kissing bonds in metallic and composite joints. Development of tomosynthesis X-ray inspection techniques.
Advanced phased array inspection of offshore mooring chain.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Non-destructive Testing
We have developed a wide range of innovative NDT solutions for our customers.
Case Study Leakage of fluids from above ground storage tanks is a major issue. Well-founded procedures have been developed for the inspection and repair of tank floors, for example API standard 653 (API 2007), but the operations required to empty, clean and make safe tanks for regular internal examinations are costly and time-consuming. The monitoring technology which has been under development at TWI for a number of years involves the use of low frequency ultrasound to examine the whole of the tank floor from a number of permanently attached sensors around the perimeter on the outside. This system allows the operators of tank facilities to obtain an early indication of a developing flaw enabling efficient scheduling of any necessary repairs.
Low frequency ultrasound detection of tank flaw
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Steve Shi Manager, Corrosion and Surfacing
Lukas Suchomel Test solution transfer to test vessel
Achievements in 2011
Assessment of the performance of polymer lined pipe to assess annulus corrosion/cracking resistance and polymer permeation/ degradation. Functional coating on composites for aerospace applications. Development of knowledge and data on the effect of hydrogen from cathodic polarisation, on the properties of ferrite-austenite interfaces encountered in duplex stainless steels and dissimilar metal interfaces. Establishment of facilities for testing materials in supercritical CO2/H2S environments. Facilities for simulating high temperature corrosion conditions in biomass/waste-to-energy power plants.
Plans for 2012
Testing of the creep performance and Type IV cracking resistance of welded materials. Extensive work on testing the effects of gaseous hydrogen on materials performance. Further development of knowledge and data on hydrogen embrittlement of subsea structures. Develop thermal spray coatings with advanced functionality on polymer composite substrates. Establishment of global metallurgical laboratory access to support Members worldwide.
Testing facilities for corrosion fatigue, sulphide stress/stress corrosion cracking and fracture testing.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Metallurgy, Corrosion and Surfacing
Our team will continue to provide timely responses and support for failure characterisation, materials performance testing and surface engineering by close interaction with customers.
Case Study TWI has designed and constructed a new high temperature test facility for assessment of material performance in environments containing up to 1000ppm HCl in air, at ambient pressure and temperatures up to 600°C. Concentrations >200ppm HCl can only be provided as a gas (from cylinders containing a maximum of 1%HCl) which requires additional safety measures including gas detection sensors and restricted access for personnel, because the short term exposure limit for HCI gas is 5ppm. The facility has been used on a current Group Sponsored Project ‘Development of Coating Technologies for High Temperature, ChlorineInduced, Corrosion Mitigation in Biomass, Waste to Energy and Other Process Plants’ to evaluate the performance of coated superheater tubes for boiler applications. It comprises two 10kW front loading kilns, which incorporate corrosion test cells (335mm internal diameter x 470mm long), manufactured from 316 stainless steel. These can support testing of samples for several months at a time with continuous temperature monitoring. Samples can be tested with or without molten salt mixtures. These can be introduced using alumina crucibles containing the appropriate salt mixtures and samples. Due to the capacity of the cells, the facility can be used for testing other materials subject to gaseous HCl attack in other industrial applications.
Neil Masters High temperature HCI testing facility
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Rob Scudamore Manager, Electron Beam, Friction & Forge and Laser & Sheet Processes
Daniel Corby Non-vacuum electron beam equipment
Achievements in 2011
Improvement in linear friction welding capabilities. Hybrid laser-MIG welding of aluminium alloy butt joints with adaptive control. Novel friction stir welding bobbin tool design developed for welding thin section aluminium alloys. First application of the reduced pressure electron beam welding out-of-vacuum-chamber mobile local vacuum sliding seal. Selective laser melting manufacture of valve components for oil and gas applications.
Plans for 2012
Develop further friction stir welding of steel. High brightness electron beam development. Dismantling and decommissioning by laser cutting. Laser metal deposition for surfacing and repair for aerospace and power sectors. Near-net shape generation using friction welding.
Selective laser melting of complex shapes.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Electron Beam, Friction & Forge and Laser & Sheet Processes
TWI is always seeking to develop joining technologies that provide added value for our Members including reducing costs and increasing quality and productivity.
Case Study Electron beam (EB) welding is often used for its unique ability to produce low distortion welds in thick section materials in a single pass. To enable deep welding and ensure high integrity the process is carried out in a vacuum chamber which effectively limits the size and geometry of the assembly which may be welded. Component-specific static chambers can be used to maintain a vacuum local to the weld region but are inflexible and expensive to implement. TWI’s solution to this challenge is the mobile local vacuum sliding seal which is able to travel across a surface maintaining a vacuum only at the point of beam/material interaction. Today the technology, enabled in part by TWI’s patented reduced pressure electron beam gun, has been applied to the welding of C-Mn steel plates of up to 60mm thickness and large tubulars of <2m diameter and 40mm wall thickness.
Local vacuum sliding seal equipment
The technology is of interest for fabrication of large pressure containment vessels for conventional and nuclear power generation. These applications will be demonstrated during 2012 in thick section C-Mn and stainless steels. Another key driver for a move to EB welding is the increase in productivity which can be achieved through reducing timeconsuming multi-pass welding and intermittent inspections.
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Sayee Raghunathan Manager, Manufacturing Support
Nigel Allison Manual metal arc welding
Achievements in 2011
Welding engineering support contracts to Member companies. Consultancy and repair qualification/validation in nuclear and oil and gas plant. Led the production of guidance on welding best practice for the nuclear new build. Won a major contract from F4E for provision of engineering support in materials joining and non-destructive testing technologies for production of ITER components.
Plans for 2012
Pursue opportunities for low carbon energy initiatives including wind and nuclear. Continue support of nuclear waste management/decommissioning and nuclear new build programmes including fusion. Expand on- and off-site welding engineering support services through a global network. Continue knowledge, innovation and technology management services in the health/medical and energy sectors. Develop processes to enable high productivity fabrication of thick section structures for oil and gas and offshore wind.
Engineering support services through a global network.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Manufacturing Support
Over 52 technical support contracts and publically funded technology transfer projects for SMEs provision of welding engineering support.
Case Study A decline in the number of experienced welding professionals has seen growing demand from TWI Members for short term welding engineering support at Cambridge or as on-site contract staff. One such instance was support for subsea production systems at Cameron International Corp during the Total Usan project. TWI welding engineers were engaged in project offices in the UK and Nigeria reviewing welding packages, welding specifications and records, post-weld heat treatment procedures and records. The total was over 8500 man-hours from November 2008 to October 2011. There is also a growing demand for the Welding Fabricator Certification Scheme which allows welding fabricators to demonstrate compliance with EN ISO 3834 and EWF requirements. This is becoming a contractual requirement within the construction and oil and gas sectors and has led to increased demand for software tools for welding documentation management. TWI has developed a customised Welding Coordinator for 200 users at five nuclear and fossil plants for Constellation Energy (now owned by Exelon Energy) in the USA. This software includes rules for fossil, gas and nuclear plants. It generates preheat and PWHT requirements based on ASME, ANSI and AWS codes and integrates the documentation associated with welder qualifications, welding procedures and fabrication plans.
TWI Certification five year assessment audit
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Roger Wise Manager, Advanced Materials and Processes
Matt Robson Micro friction stir welded heat sink
Achievements in 2011
The first friction stir welds in short fibre-reinforced thermoplastic composites were carried out. The first nano-meter scale welds in polymers using Clearweld were achieved. A new method for welding continuous carbon fibre thermoplastic composite materials from the inside was developed. Development of a system to detect and measure the presence of asbestos particles for the construction industry.
Plans for 2012
Continue to develop microwave processing of polymer composites for aerospace and other industries. Develop further non-destructive testing of welds in thermoplastic pipes for the gas and water industries. Development of an oxy-hydrogen flame for safer brazing of metallic piping systems. Further development of tests for polymers operating in extreme environments. New approaches planned for the pre-treatment of polymer surfaces for adhesive bonding.
Microwave processing of polymer composites.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Advanced Materials and Processes
We continue to demonstrate the ability to generate new ideas to satisfy the needs of our clients.
Case Study As part of a recent collaborative project, TWI produced a ceramic demonstrator by the laser fusion of ceramic particles. This demonstrator, manufactured from alumina powder, has high density with no evident voids or cracks even when viewed under optical microscopy. Small-size ceramic parts are difficult to produce and mould by conventional sintering methods (eg using furnaces). As a result this work is directed towards exploitation in electronics and medical applications where we could potentially offer new ways to manufacture dental and orthopaedic products. Although alumina has been chosen for the initial study, the technique is expected to be equally applicable to a range of other technical ceramics, providing a new way to rapidly manufacture precision products.
Ceramic demonstrator made by laser fusion of ceramic particles
The research leading to these results has received funding from the European Community's Framework 7 Programme.
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Lukas Suchomel H2S laboratory
Industry Sectors
Richard Freeman Manager, Aerospace Sector
Achievements in 2011
An international Linear Friction Welding seminar was held in March with over 40 attendees. Hosted the Friction Stir Spot Welding International Committee meeting in September. Presented three papers at the Aeromat conference in California in May and one at the Airtec conference in Frankfurt. TWI is one of four R&D partners in the UK-based Manufacturing Technology Centre and is working with industrial partners on the delivery of several projects in the High Integrity Fabrication area.
Plans for 2012
One Aerospace Panel meeting to take place in March alongside aerospace-related GSPs. The 6th Joint TWI/EWI Symposium on Joining of Aerospace Materials will take place in Munich in September, supported by MTU. Three papers will be presented at the 2nd European Titanium Conference in Bristol in March. Six TWI papers were presented at the Aeromat conference in Charlotte in June. TWI will be exhibiting at the Farnborough Air Show in July to enable Members to discuss their welding and joining needs.
Exhibiting at the Farnborough Air Show to enable discussion with Members of their fabrication requirements.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Aerospace
TWIâ&#x20AC;&#x2122;s Industrial Members include 15 of the top 20 aerospace companies in the world.
Case Study TWI took delivery of a 20 ton production linear friction welding machine from Thompson Friction Welding in September. The machine was installed and commissioned in time for the mid-September Aerospace Panel meeting, attended by 40 people from the leading aerospace companies around the world. Demonstration welds were made during their visit to the Friction Laboratory. This investment will allow TWI to support Members in the development of prototype production parts, such as bladed discs (blisks) and for components built up by linear friction welding to reduce the buy-to-fly ratio by significantly reducing the amount of titanium machined.
Linear friction welding machine
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John Davenport Manager, Automotive Sector
Mark Tinkler Lap shear tensile testing
Achievements in 2011
11% increase in Industrial Membership. Continued to grow the portfolio of single client projects concerning electric/hybrid vehicles. Two EU collaborative projects launched focused on the reliable manufacture and post-crash repair of spot welds. Joined the Bloodhound SSC land speed record team to supply expertise on joining technologies. Further development of robust metallic coatings on composites offering new solutions to thermal management issues.
Plans for 2012
Automotive Member Day planned for October 2012. Installation of a newly approved resistance spot welding cell at TWI Cambridge to accelerate innovation with new materials and processing options. Further development of technologies suited to joining applications for electric/hybrid vehicles. Focus on increasing the Technology Readiness Level of microwave curing of composites for more rapid curing. Explore options for reducing through-life costs of tooling used for the production of automotive composite components.
Development of joining technologies for electric/hybrid vehicles.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Automotive
The increasing use of mixed materials in vehicles requires ever greater attention to joining requirements.
Case Study Zytek Automotive is a specialist powertrain and vehicle engineering enterprise delivering value to its clients with innovative engineering solutions. Its focus has developed to cover the electric and hybrid-vehicle sector where it has a track record in solving complex engineering challenges for production vehicle projects. As part of on-going development work, Zytek has a requirement to join four copper conductors each of approximate cross-section 9 x 1.25mm to a copper bus bar 9 x 5mm in cross-section. All parts are manufactured from Grade 2 copper and coated with a polyimide insulating material.
courtesy of Zytek
TWI reviewed the assembly and proposed three approaches likely to achieve acceptable joints in terms of electrical and mechanical performance. These were friction stir welding, tungsten inert gas (TIG) welding and soldering. Zytek decided to proceed with an investigation of TIG welding and soldering. With regard to soldering, TWI recommended that a technique for stripping the polyimide coating and preparing the copper was developed so a consistent and even joint gap is achieved to assist with solder flow through the joint and retention within the joint.
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Amir Bahrami Manager, Oil, Gas and Chemical Sector
David Drew Resonance testing
Achievements in 2011
Full scale fatigue testing of riser pipes in sour environments for deepwater applications. Progress towards the revision of BS 7910 to improve ECA methodologies. Methodologies and techniques for ECA of pipe-in-pipe systems. Extension of sour service testing facilities for corrosion fatigue, sulphide stress cracking/stress corrosion cracking and fracture testing. Establishment of facilities for high pressure/high temperature testing.
Plans for 2012
Qualification of high strength mooring chains. Developing harmonised approaches for assessing fracture properties of steel under hydrogen charged conditions. Upstream (offshore) risk-based inspection. Automation of collapse load and stress intensity factor calculations for pipeline girth welds. Develop new technologies for the monitoring and early detection of offshore coating failure.
Early detection of offshore coating failure.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Oil, Gas and Chemical
TWIâ&#x20AC;&#x2122;s technical consulting arm in Houston, Texas now supports Industrial Members throughout the USA.
Case Study Metallic pipelines operating in high pressure CO2-containing impurities such as H2S experience corrosion and cracking issues. Under such extreme conditions, a major technical challenge is quantifying degradation of different transport components, including pipes, welds and pumps, in CO2 as a high pressure gas or as a supercritical fluid, particularly in the presence of H2S. Although there is considerable experience of testing materials in lower pressure CO2, there are no standard test methods and few data for supercritical CO2. To address these issues TWI initiated a Joint Industry Project where corrosion rates and cracking data of various representative pipeline alloys were experimentally determined. This information is likely to allow confident new build design and better evaluation and re-use of existing pipelines which are in contact with supercritical CO2-containing fluids.
Chi Lee Sour service corrosion fatigue
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Sayee Raghunathan Manager, Power Sector
Kyle Power Electron beam welding equipment
Achievements in 2011
Produced fabrication standards for for demonstration of a floating wind turbine concept. Extension to the contract to deliver the Energy Generation & Supply Knowledge Transfer Network on behalf of the Technology Strategy Board. Demonstration of advanced fabrication techniques for offshore wind foundations through the MANOS project.
Plans for 2012
The Power Sector Panel Meetings re-established with an inaugural meeting in April on repair of high temperature steels for fossil plant. A second meeting is scheduled for Quarter 4 2012. A focused list of fossil plant repair project topics will be developed in collaboration with Power sector members. Broaden involvement in the carbon capture arena through initiatives in structural integrity for transportation, CO2 monitoring and carbon capture media. Condition management technology and supporting services for on and offshore wind turbines will be developed.
TWI selected to advise on the International Thermonuclear Experimental Reactor.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Power
TWI continues to grow in all sectors of the power market.
Case Study TWI has been awarded a major framework contract to support the fabrication of key components of the ITER nuclear fusion reactor, by Fusion for Energy (F4E), the organisation delivering the European contribution to the ITER International Fusion Energy project. It will be the world’s largest experimental fusion facility and is designed to demonstrate the scientific and technological feasibility of fusion power. The four-year contract will see TWI (with subcontractors Ceram and The Test House) provide engineering support to F4E on the performance of materials, joining, structural integrity of joints and non-destructive testing activities in support of the manufacture of components such as the vacuum vessel, magnets system, remote handling equipment and in-vessel parts. The core of ITER is the ‘Tokamak’ based doughnut-shaped vacuum vessel in which plasma is heated and confined in magnetic fields, as no solid material could withstand the extremely high temperature of the plasma necessary for fusion to occur at around 150 million degrees Centigrade. The support TWI will provide to F4E will include: engineering and materials studies; assessment and testing of joining technologies including destructive and nondestructive testing; specification of design and manufacturing procedures; failure analysis; technical audits; ensuring appropriate certification, validation and qualification of all procedures and personnel involved in the build of components for the reactor.
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John Davenport Manager, Construction and Engineering Sector
Colin Eileens Classic vehicle chassis
Achievements in 2011
Friction stir welding of steel for application in the off-highway and land defence sectors. Major contract secured for specialist manufacture of components for the defence sector. Assistance provided to industry on the repair and life extension of civil infrastructure assets. TWI’s risk-based asset management expertise applied to the construction and engineering sector, particularly within the rail sector. Widespread use made of training and CSWIP examination of competency for the welding of geomembranes for use at landfill sites.
Plans for 2012
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Development of robust, cost effective condition monitoring approaches working with bridge owners, civil engineers and other stakeholders. Continuing growth in defence activities based on TWI’s technical expertise and new facilities which allow work to be conducted under conditions of very high security. Increase the technology readiness levels of innovative approaches to assist the rail sector in overcoming current limitations with track inspection and condition monitoring techniques. Continue to assist Industrial Members with the introduction of composites, particularly in transport applications. Contribute to the EU project HIPIN which is aimed at developing high performance insulation for buildings at an affordable price.
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Construction and Engineering
More and more Industrial Members are seeking TWIâ&#x20AC;&#x2122;s assistance with riskbased through-life asset management.
Case Study From time to time Industrial Members have issues with components in service where it is not possible to remove samples for subsequent investigation at TWI facilities. Industrial Member Quartzelec contacted TWI for help when an installed steel retaining band was splattered with molten copper. Since liquid metal penetration is known to cause embrittlement of stainless steel this issue warranted urgent investigation. After a study of the damaged area and high magnification photography, TWIâ&#x20AC;&#x2122;s technical specialists identified representative regions for closer consideration. These regions were cleaned, polished and etched to reveal the underlying grain structure. Replicas of each etched surface were then taken using acetate film and returned to TWI for further analysis. Detailed examination showed no evidence of liquid metal damage. The evidence obtained allowed the retaining band to continue safely in service with the knowledge that its performance had not been impaired.
Develop high performance insulation for buildings. courtesy of Quartzelec
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Norman Stockham Manager, Electronics, Photonics, Sensors and Nanotechnology
Helen Goddin Wire bonding
Achievements in 2011
Successful launch of a series of collaborative projects including: High temperature electronics, precision passive components and micro-friction stir welding. Expanded project work on the joining of copper and aluminium conductors for electrical terminations. Conducted state-of the-art reviews on PCB selective soldering and cleaning. Increased activity on solder joint quality and performance. Initial development of radiography technology for detecting counterfeit components.
Plans for 2012
Develop new initiatives on power electronics and thermal management. Continue growth in high temperature, harsh environment operating environment sensors and electronics. Launch Group Sponsored Project on materials and packaging for high temperature electronics and sensors. Explore further opportunities within the electronics, sensors and photonics sector, using TWI’s micro-laser and prototyping expertise. Increase engagement with the sector in the key areas of sensor technology, product reliability and manufacturing systems.
Micro-laser and prototyping expertise.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Electronics, Photonics, Sensors and Nanotechnology
Increased activity in this sector resulted in significant growth, exceeding targets for single client and collaborative projects and new membership.
Case Study Counterfeit electronic components are a growing issue to the electronics industry and the safety consequences of of their inadvertent use in products for the aero, auto, nuclear, medical, critical plant control and electronics consumer industries cannot be overstated. To address this problem TWI is managing an EU Framework 7 project called ChipCheck, developing a counterfeit electronic component detection system that will automatically inspect components in their original packaging. Currently, manufacturers cannot check all components at goods inwards. ChipCheck seeks to address this with the development of a new inspection prototype. A number of non-destructive testing methods are being investigated and developed to establish the best detection method that can be automated. The project has released the world’s first training CD on this important subject. ChipCheck is a collaboration with the following partner organisations: Innospexion APS, Accent Pro 2000 s.r.l, Computerised Information Technology Ltd, Semicon Sp. z o. o., Kentro Erevnas Technologias Kai Anaptyxis Thessalias, Surface Mount and Related Technologies Ltd, Elektronikas un datorzinatnu instituts. The project is supported by the European Community’s 7th Framework Programme managed by REA-Research Executive Agency.
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Chris Wiseman Manager, Equipment, Consumables and Materials
Mark Tiplady and Nigel Allison TIG welded aeroplane component
Achievements in 2011
Twelve per cent growth in the number of Industrial Members, and the amount of specific project work dedicated to the sector. Continued to deliver value through commercially targeted initiatives that are exclusive to TWI Industrial Members. For example, our Industrial Trends Analysis which has been delivered to a record number of recipients. Upgraded and re-launched our Members Showcase facility, offering the opportunity for even greater visibility of our Members’ products and services via the TWI website. Participation in legislative procedure around the world and have advised and represented our Industrial Members regarding evolving legislation in topics in which we have dedicated capabilities and expertise. Delivered several individual Company Events for our Industrial Members which show benefit through creation of key networks and updating mutual awareness between TWI and Member Companies.
Plans for 2012
Consult with ECM Members to offer events for companies with a common industry sector focus. Disseminate to Members the value of the MI21 database and encourage their feedback and participation in determining most appropriate content. Extend usage and update content of Member Showcase. Encourage TWI participation in targeted Member company forums and virtual events.
Updated Member company content in Member Showcase webpage on TWI website.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Equipment, Consumables and Materials
Our services for this sector deliver direct technical and commercial value for our immediate clients and opportunities within the wider TWI Industrial Membership community.
Case Study TWI was asked to test a new water-based product and automated application system for robotic welding by an Industrial Member when it wanted to develop a new product. The product, Ceramishield RobotIQÂŽ made by the Industrial Member Henkel, is a system to apply a dry film coating to protect welding torch components from welding spatter for extremely long periods of time compared to typical anti-spatter products on the market and was to be used in an automated robotic configuration. The brief was to establish the equipment settings needed to achieve a good coating on the torch components for a reasonable length of time, assess the coating performance of the coating and to comment on the coatingâ&#x20AC;&#x2122;s impact upon the weld quality, productivity and cost savings. Spraying conditions were optimised and trials were carried out to assess the capability of the coating to prevent spatter build up when used in conjunction with a magnetic torch cleaner. For calibration purposes comparison trials were carried out without applying the anti-spatter spray. The unit was easily interfaced to the robot used for the trials. The spray coating performed well and the magnetic torch cleaner removed most of the spatter. Welding was carried out for up to four hours without needing to replace the shroud or contact tip. In the interests of commercial independence and impartiality TWI does not endorse the products and services of its Industrial Members.
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Tom Setterfield Manager Training & Examination Services United Kingdom
Ernie Moskini Regional Manager Training & Examination Services South East Asia
Brian Hunt Regional Manager Training & Examination Services Middle East
Jim Kerins Regional Manager Training & Examination Services India
Farshid Alizadeh Regional Manager Training & Examination Services Central Asia
Financial Performance Growth in TWI’s Training & Examination business continues, both in the UK and overseas. The UK in particular has had an excellent year, achieving financial growth beyond budget; this is partly due to the introduction of focused sales and marketing which had particular success in identifying strong demand for TWI’s CSWIP training products in South Africa, likely to continue for the foreseeable future. Global Expansion For some time, TWI has been active in delivering training in India, with both UK and Middle East providing resources to service this region. As a result of sustained growth within the Indian sub-continent, TWI made the strategic decision to open a local office in Chennai and employ a manager in the region. Jim Kerins joined as Manager for India on 1 September 2011 and began the task of finding suitable premises and recruiting a local workforce. There continues to be evidence of growing global demand for qualified and competent personnel to manage welding activities in industry. Strong growth in demand for TWI’s diploma course on welding technology is being seen, with training course numbers in the UK increasing and several courses being run in SEA. TWI’s most popular course for welding inspection has now been translated into Chinese to facilitate delivery in this region with courses having been run with encouraging results.
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Training & Examination Services
Quality, integrity and industrial relevance underpin all TWI’s training activities.
Stephen Jones Welding inspection training
New Products To maintain its enviable position in the training marketplace, TWI operates a process of continuous renewal for its products. In 2011 TWI launched a new Plant Inspection Level 2 course, which provides individuals with a better structure for career progression. Some regions of the world are less accessible to traditional methods of training delivery, therefore TWI began the development of an e-learning platform for delivery of some of its course content. This is currently a pilot project which provides an understanding of the important factors associated with this kind of delivery as well as the impact on its business processes. TWI’s first e-learning product should be launched in 2012. Integrity Examination security is the underpinning to the TWI and CSWIP brand and to ensure that this brand is not undermined, extensive work was carried out in 2011 to expand the database of examination questions. Exams can now be created from this database at random, ensuring a much greater number of examination scripts.
TWI’s e-learning platform under development.
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Steve Shi with overseas visitors
TWI Industrial Member Companies
TWI Industrial Member Companies
Algeria BP Amoco Exploration (In Amenas) Ltd ConocoPhillips Algeria Ltd JGC Algeria SpA
Technip Oceania Pty Ltd ThyssenKrupp Materials Handling Pty Ltd Total Australia Ltd Toyota Motor Company Australia United Group Rail Wood Group Integrity Management Woodside Energy Ltd
Austria
Angola Cameron Valves & Measurement West Africa Ltd MODEC Angola Lta Total E&P Angola
Argentina Air Liquide Argentina SA Conarco Alambres Soldaduras SA Esab Argentina SA TenarisSiderca
DAU Ges mbH & Co KG EBG & DAU Kühlerentwicklung GmbH Elektronische Bauelemente GmbH ESAB GesmbH Hammerer Aluminium Industries GmbH IGM Robotersysteme AG MED-EL Medical Electronics PLANSEE SE Winkler Solar GmbH
Azerbaijan
Australia AACE Pty Ltd Air Liquide Australia Ltd Applus RTD Australia Applus RTD Project Services Australia Pty Ltd Aspec Engineering Pty Ltd Australian Nuclear Science & Technology Organisation (ANSTO) BAE SYSTEMS Australia BHP Billiton Petroleum Pty Ltd BP Refinery (Bulwer Island) Ltd BP Refinery (Kwinana) Pty Ltd Callidus Welding Solutions Pty Ltd Caltex Australia Petroleum Pty Ltd Caterpillar of Australia Ltd Chevron Asiatic Ltd Chevron Energy Technology Pty Ltd Cladtek International Pty Ltd Cochlear Limited Cummins South Pacific (Cummins ReCon - Australia) DSTO (Australian Government) ESAB Australia Pty Ltd Esso Australia Ltd Fluor Daniel Australia Ltd Gladstone LNG (GLNG) Goninan Engineering & Design Goninan North Queensland Pty Ltd Gorgon Upstream Joint Venture Hitachi Australia Ltd INPEX Browse Ltd INTECSEA Pty Ltd Joy Mining Machinery (Australia) Linde Gas Pty Ltd MainTrain Auburn Service Centre MCA Australia Group MCA Australia Pty Ltd Nippon Steel Australia Pty Ltd QGC Pty Richard Eager Pty Ltd Saipem Australia (Pty) Ltd Santos Ltd Shell Refining (Australia) Pty Ltd Talisman Australasia
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BP Exploration (Caspian Sea) Limited
Bahrain BAPCO
Bangladesh Shell Bangladesh Exploration & Development BV
Belgium Air Liquide Belge SA Air Products NV/SA Aisin Europe SA Aleris Aluminium - Rolling Division Europe ArcelorMittal Belgium NV ArcelorMittal Ghent ArcelorMittal Research Industry Gent/OCAS BP Chembel NV Caterpillar Belgium SA Cytec Surface Specialties SA/NV Emerson & Cuming Fina Antwerp Olefins NV Fina Chemical Antwerpen NV Fina Feluy FMC Europe NV Lincoln Smitweld Belgium NV SA ESAB NV Sapa RC Profiles NV/SA Shell Louvain-la-Neuve Shell Research SA Tailor Steel NV Total Raffinaderij Antwerpen NV Toyota Motor Engineering and Manufacturing Europe Volvo Construction Equipment Volvo Europa Truck NV
Bolivia Total E&P Bolivia
Brazil Air Liquide Brasil Arcos Solda Electrica Autogena SA Bureau Veritas do Brasil - Oil & Gas Division Cameron (Brazil) Caterpillar Brazil SA Confab Industrial SA Confab Tubos SA Cummins Brazil (Cummins ReCon - Brazil) Embraer ESAB SA Industria e Comercio Esso Brasileira de Petróleo Ltda Flexibrás Tubos Flexíveis Ltda FMC Technologies do Brasil Ltda INTECSEA do Brasil Ltda MODEC Serviços de Petróleo do Brasil Ltda Oil States Industries do Brasil Ltda PETROBRAS PETROBRAS - SEQUI PETROBRAS/Refinania de Paulinia PETROBRAS E & P PETROBRAS TRANSPORTE SA PETROBRAS/AB-RE/ES/TEE PETROBRAS/CENPES PETROBRAS/CENPES/PDEP/TMEC PETROBRAS/CENPES/PDEP/TS Petroleo Brasileiro SA - PETROBRAS SBM do Brasil Shell Brasil Statoil do Brasil Ltda Subsea7 Brazil SA TBG Technip Brazil - Engenharia, Instalacoes e Apoio Maritimo Transocean Brazil V & M do Brasil SA Volvo Construction Equipment South America
Brunei Brunei Shell Petroleum Co Sdn Bhd
Cameroon Total E&P Cameroon
Canada AECL CANDU Air Liquide Canada Applus RTD Canada Atomic Energy of Canada Ltd BP Canada Energy Company CANMET Materials Technology Laboratory Caterpillar of Canada Ltd Chevron Canada Resources Ltd Eclipse Scientific
Elliott Turbomachinery Canada Inc ESAB Group Canada Inc Esso Resources Canada Ltd Evraz Inc NA ExxonMobil Canada Fluor Canada Ltd GKN Walterscheid Canada Inc Hitachi Canadian Industries Ltd Imperial Oil Engineering Services Co Intelligent Engineering (Canada) Ltd Messier Dowty Inc Rolls-Royce (Canada) Ltd Servo Robot Shell Canada Ltd Subsea7 Canada Inc Talisman Energy Inc Technip Canada Limited TenarisAlgomaTubes TransCanada PipeLines Ltd Volvo Motor Graders Ltd Volvo Road Machinery Ltd
China, Peoples Republic of Air Products China Autoliv (China) Inflator Co Ltd AVIC Beijing Institute of Aeronautical Materials Baoshan Iron & Steel Co Ltd Baosteel Industry Inspection Ltd Beijing Aeronautical Manufacturing Technology Research Institute BOC Gases China China Academy of Launch Vehicle Technology China Aero-Polytechnology Establishment China FSW Center China Offshore Oil Engineering Corporation COMRI Cummins Xiangfan Machining Co Ltd (Cummins ReCon - China) Danfoss Refrigeration Equipments Tianjin Co. Ltd ESAB Representative Office F.tech Wuhan Inc F.tech Zhongshan Inc Fluor China Fujian ShanWaiShan Coating Science and Technology Delevop Co Ltd General Research Institute for Non-Ferrous Metals Hefei General Machinery Research Institute Junguang Industry Development Co Ltd TJPRC Lloyds Register Asia Shaanxi Guode Electric Co Ltd Shanghai Aerospace Equipment Manufacture Shanghai ESAB Cutting Co Shanghai Greens Thermal Equipment Shipbuilding Technology Research Institute of CSSC Wuhan Iron & Steel (Group) Corporation Xi’an Sunward Aerospace Material Co Ltd Hong Kong CLP Power Hong Kong Limited - Generation Business Group
TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
Taiwan Air Liquide Taiwan China American Petrochemical Co Ltd Vette Taiwan Ltd
Columbia Talisman (Colombia) Oil and Gas Ltd Tubos del Caribe SA - TuboCaribe
Croatia Saipem Mediterranean Services LLC
Czech Republic ESAB VAMBERK as EWM Hightec Welding sro Skoda Power sro
Denmark Danfoss Industrial Automation Danfoss Refrigeration & Air Conditioning Controls Danfoss Refrigeration and Air Conditioning Division Dansk Shell A/S Raffinaderiet ESAB A/S Grundfos A/S Grundfos Management Hede Nielsen NKT Flexibles I/S PDC-Teknik A/S Sapa Mass Transportation
Egypt BP Egypt Hitachi Plant for Steel Construction
Finland Cavitar Ltd ESAB OY Kitkahitsaus Jori Oy Oy Hardy Spicer AB
France ACB AEROLIA AEROLIA MÉAULTE Air Liquide Air Liquide - CEPIA Air Liquide Welding Air Liquide/CTAS Air Products Airbus Operations SAS Airbus SAS Alfa Laval Packinox Alfa Laval Vicarb
Aliaxis R&D Aliaxis R&D - SAS (on behalf of Aliaxis Utility Sub-division) ANDRA AREVA NC AREVA NC BU Assainissement AREVA NP AREVA NP - Thermonuclear Fusion Projects AREVA NP SAS AREVA TA Cameron France SA Caterpillar France SA CERCA CNIM Comex Nucleaire Constellium (Research Center - Voreppe) Danfoss Commercial Compressors DCNS Propulsion EDF CIDEN EDF CIT EDF Nuclear Engineering Division - SEPTEN EDF R&D EDF SA EDF UNIE EDF UTO ESAB France SA ESAB SA ESSO-SAF Eurocopter Flexi France SA FMC Europe SA FMC Technologies Company (US) FRESA Honeywell Turbo Technologies Inteva Products ITER Organization Jehier SA Leroy-Somer Lincoln Electric France SA Livbag SAS Messier Dowty SA Metrode France SARL NCS (Survelliers) Oerlikon - CTAS Oerlikon-Soudure France Sarl ONET Technologies Polysoude SAS Renault Trucks SAF SAFMATIC SAFRAN GROUP Saibos Construcoes Maritimas Lda Saipem SA Sapa Profiles Albi snc SCS Serimax SETVAL - CEV Sitia Snecma Snecma Evry-Corbeil Snecma Services Snecma Vernon Snecma Villaroche Sogedec Soudure Autogene Francaise - SAF Subsea7 France SA Tata - Rail Products Techlam SA Technip
Technip France TN International Total Total E&P France Total Fina Elf-CERT Total Petrochemicals France Total SA Vallourec Mannesmann Oil & Gas France
Germany Air Liquide GmbH Airbus Operations GmbH Arc Machines GmbH AREVA NP GmbH Bauknecht Hausgeräte GmbH Branson Ultraschall BROETJE-Automation GmbH ConocoPhillips - Wilhelmshaven DEKRA Industrial GmbH Emerson Climate Technologies GmbH ESAB Cutting System GmbH ESAB GmbH European Aeronautic Defence and Space Company NV EWM Hightec Welding GmbH EWM Schweisstechnik Handels GmbH Fluor Daniel GmbH Friatec Fusion for Energy GKN Driveline International GmbH GKN Walterscheid GmbH H Butting GmbH & Co KG Helmholtz-Zentrum Geesthacht Henkel Adhesives Technologies (AR) Henkel AG & Co KGaA Hitachi Europe GmbH IHI Charging Systems International GmbH Johnson Controls GmbH - Technology & Advanced Development Kawasaki Robotics GmbH Deutschland Lincoln Smitweld GmbH Linde Group Lurgi GmbH MT Aerospace AG MTU Aero Engines GmbH MTU Maintenance BerlinBrandenberg GmbH MTU Motoren-und TurbinenUnion Munchen GmbH Oerlikon Schweisstechnik GmbH PFW Aerospace AG Pierburg GmbH pro-beam AG & Co KGaA RIFTEC GmbH Rolls-Royce Deutschland Ltd & CO KG Shell Deutschland Oil GmbH Siemens AG, Energy Muelheim Tata Aluminium Profiltechnik Bonn GmbH Tata Hille & Müller GmbH Total Mitteldeutsche Erdoel Raffinerie GmbH Toyota Motorsport GmbH Tyco Thermal Controls GmbH Volvo Compact and Service Equipment GmbH
Ghana Shell Ghana Ltd
Greece Air Liquide Hellas SA Corinth Pipeworks SA
Hungary ESAB Kft
India Air Liquide India Holdings Pvt Ltd CIMTAS Boru IML TIC Ltd STI Cummins Recon India Engineers India Ltd ESAB India Ltd ETA Technology PVT Ltd ISRO (LPSC Unit at Valiamala) Larsen & Toubro Limited - Engineering & Construction Projects (E&C) Divn Larsen & Toubro Limited - Heavy Engineering Independent Company MTI-Nash Friction Welding PVT Ltd Oil and Natural Gas Corporation Limited Saipem India Project Service Ltd Shell Technology India Pvt Ltd TATA Steel Ltd - Growth Shop Technip KT India Ltd Texmaco Limited Toyota Kirloskar Motor Pvt Ltd TVS Motor Company Volvo Construction Equipment India
Indonesia Air Liquide Indonesie BP Berau Ltd BP Indonesia BP South East Asia BP Tangguh Development Chevron Pacific Indonesia ConocoPhillips Indonesia Inc ExxonMobil Oil Indonesia FMC Santana Petroleum Equipment PT Pertamina Hulu Energi ONWJ Ltd PT Esabindo Pratama PT JGC Indonesia PT Karya Yasantara Cakti PT Komaritim PT Nippon Steel Batam Offshore Service PT Nippon Steel Construction Indonesia PT Saipem Indonesia Saipem Indonesia Talisman (Asia) Ltd Total E&P Indonesie (DKP/INS) Total Esp Indonesia Total Indonesia Total Indonesie PT
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Ireland, Republic of Aughinish Alumina Ltd Boston Scientific CRM Boston Scientific Ireland BS&B Safety Systems Ltd ESB Power Generation ESBI Engineering & Facility Management Ltd Henkel (Ireland) Ltd Hibernian Wind Power Odenberg Engineering Ltd SR Technics Airfoil Services Ltd Timoney Technology Group
Italy AGIP SpA Serv Nost Air Liquide Italia Service Srl Air Liquide Italia Srl Air Liquide Welding Italy Alfa Laval Olmi SpA AM srl Bytest srl Cameron Italy SRL Centro Sviluppo Formazione COOLTECH srl Elliott Turbomachinery SA ENI SpA - Exploration & Production Division ESAB Saldatura SpA ETC Elettrotermochimica ExxonMobil Oil Italiana SpA FMC Technologies Italia SpA ILVA SpA IMS Industrie Meccaniche Scardellato SpA INDESIT COMPANY SpA Lincoln Electric Italia SRL Loterios SpA Mangiarotti Nuclear SpA Mangiarotti SpA Mecc.AL srl a Socio Unico Nooter/Eriksen Srl Raffineria di Roma Rosetti Marino SpA Saipem Group Saipem SpA Sirai Elettromecchanica Srl Tecnomare SpA Tenaris TenarisDalmine Whirlpool Europe Srl Whirlpool Italia srl
Jamaica Shell Co (West Indies) Ltd
Japan Air Liquide Japan Aisin Seiki Co Ltd Autoliv Japan Ltd, Aichi Facility Babcock Hitachi KK Caterpillar Japan Inc. Chida Precision Corp Daido Steel Co Ltd
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F.tech Inc Furukawa-Sky Aluminum Corp Hitachi Air Conditioning Systems Co Ltd Hitachi Construction Machinery Co Ltd Hitachi Engineering Consulting Co Ltd Hitachi High Technologies Co Hitachi Koki Co Ltd Hitachi Ltd Hitachi Ltd, Power & Industrial Systems Hitachi Plant Technologies Ltd Hitachi Setsubi Engineering Co Ltd Hitachi Via Engineering Ltd Hitachi Zosen Corporation Hitachi-GE Nuclear Energy Ltd Honda Engineering Co Ltd Honda Research & Development Co Ltd IHI Corporation ISEL Co Ltd JFE Steel Corporation JGC Corp JGC Maintenance Services Co Ltd JGC Plantech Co Ltd Kawasaki Heavy Industries Ltd Kawasaki Plant Systems Ltd Kawasaki Precision Machinery Ltd Kawasaki Shipbuilding Corporation KCM Co Ltd Keihin Ram Tech Co Ltd Kobe Steel Ltd Komatsu Ltd Kosei Aluminum Co Ltd Kyoei Manufacturing Co Ltd Mitsubishi Electric Corporation, Public Utility System Group Mitsubishi Heavy Industries Ltd - Nagasaki Research & Development Center Mitsubishi Heavy Industries Ltd - Nagasaki Shipyard & Machinery Works MODEC Inc Nabtesco Corporation Nippon Light Metal Co Ltd Nippon Sharyo Ltd Nippon Steel & Sumikin Welding Co Ltd Nippon Steel Corp Nippon Steel Engineering Co Ltd Nishinippon Plant Engineering and Construction Co Ltd Plasma Giken Co Ltd Plazwire Co Ltd Shimadzu Corporation Shinko Research Co Ltd ShinMaywa Industries Ltd Showa Denko KK Sky Techno Co Ltd Sumitomo Metal Industries Ltd TADA Electric Co, Industrial Apparatus Works TenarisNKKTubes TLV Co Ltd Tokyu Car Corporation Toyo Kanetsu KK Toyota Central R&D Labs Inc Toyota Motor Corp Yamaha Marine Co Ltd Yamaha Motor Co Ltd
Kazakhstan AGIP KCO Karachaganak Petroleum Operating BV (KPO) Saipem SpA - Kazakhstan Branch Tengizchevroil
Kenya Kenya Shell Ltd
Korea, Republic of Dongyang Gangchul Co Ltd ESAB SeAH Corp Halla Climate Control Corp Samsung Heavy Industries Co Ltd - Shipbuilding Divn Volvo Group Korea Co Ltd
Kuwait Babcock Borsig Services GmbH, Branch Kuwait BP Kuwait Limited Fluor International Limited FTV Proclad (Kuwait) Ltd Kuwait Aviation Fuelling Co (KSC) Kuwait National Petroleum Co Kuwait Oil Company Kuwait Pipe Industries & Oil Services Co KSC Petrochemical Industries Co KSC
Libya Azzawiya Oil Refining Company Inc BP Exploration Libya Ltd ENI North Africa BV Libyan Emirates Refinery Company (LERCO) Ras Lanuf Oil & Gas Processing Co Sirte Oil Company Total Libya
Malaysia BP Chemicals Malaysia Sdn Bhd BP Petronas Acetyls Sdn Bhd CRC-Evans Pipeline International Sdn Bhd Det Norske Veritas As Sdn Bhd DNV/KKA ESAB (Malaysia) Sdn Bhd Esso Production Malaysia Inc ExxonMobil Production Malaysia Inc Global Process Systems Sdn Bhd INTEC Engineering (SEA) Sdn Bhd INTECSEA Malaysia Jimah Energy Ventures Sdn Bhd Jimah O&M Sdn Bhd Jimah Power Plant Lloyd’s Register of Shipping (M) Bhd Lloyd’s Register Technical Services Sdn Bhd MFE Formwork Technology Sdn Bhd OMS Oilfield Services (Malaysia) Sdn Bhd
Petrofac E&C Malaysia Pipeline Technique Sdn Bhd Power Weld Sdn Bhd Rubitech Malaysia Saipem Asia Snd Bhd SapuraAcergy Sdn Bhd Sarawak Shell Berhad SBM Malaysia Sdn Bhd SCOMI Engineering Berhad Scomi Rail Bhd Serimax Welding Services (M) Shell Global Solutions (Malaysia) Sdn Bhd Shell Middle Distillate Synthesis (Malaysia) Sdn Bhd Shell Refining Company (FOM) Berhad Talisman (Malaysia) Ltd Technip Malaysia
Mexico Cantarall FSO Inc SA de CV Diesel ReCon (Cummins ReCon - San Luis Potosi) ESAB Mexico SA Radiografias de Campeche SA de CV TenarisTamsa
Morocco Shell Morocco
Myanmar Total E&P Myanmar TotalFinaElf Myanmar E & P
Netherlands, The Air Products Nederland BV Allseas Engineering BV Applus RTD BV Aquilex Welding Services BV Aramco Overseas Company BV Bayards Aluminium Constructies BV CRC-Evans Automatic Welding - Sales, Service & Rental DSM DSM - Sitech Services DSM Agro DSM Corporate SHE&M DSM Elastomers DSM Fibre Intermediates DSM Industrial Services BV DSM NeoResins Dutch Space BV ESAB Nederland BV Esso Nederland BV ESTEC European Space Agency, Materials & Processes Divn - ESTEC Fluor Daniel BV Fusite BV Gusto BV Heerema Engineering Service BV Heerema Group Heerema Marine Contractors Nederland BV Heerema Vlissingen BV
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Heerema Zwijndrecht BV Henkel Nederland Acheson BV Huisman Special Lifting Equipment BV Huisman-Itrec INTECSEA BV ITW Welding Products BV Kobelco Welding of Europe BV Lincoln Electric Europe BV Lincoln Smitweld BV Lloyd’s Register Nederland BV Marine Structure Consultants (MSC) BV McDermott International Inc Metrode Eurolas BV MSD National Aerospace Laboratory NLR Nederlandse Aardolie Maatschappij BV NRG Philips LightLabs Rolls-Royce Marine Benelux BV Rubitech Heating BV Rubitech Holding BV SABIC Europe Sapa Aluminium BV Sapa RC System BV Shell Global Solutions International BV Shell International Chemicals BV Shell International Exploration & Production BV Shell International Oil Products BV Shell Internationale Petroleum Mij BV Shell Nederland Raffinaderij BV Shell Research and Technology Centre Shell Research BV Shell Solar Shell WindEnergy BV SIF Group BV Sitech Manufacturing Services CV Stamicarbon BV Stoomwezen BV Tata Packaging Plus Tata Research, Development & Technology Tata Strip Products NL Total E&P Nederland BV Total Raffinaderij Nederland NV
New Zealand BOC Gases New Zealand Limited Buckley Systems Ltd Optimech International Ltd Shell Todd Oil Services Ltd
Nigeria Cameron Offshore Systems Nigeria Ltd Chevron Nigeria Limited Elf Petroleum Nigeria Ltd ExxonMobil Development Company Nigeria ExxonMobil Producing Nigeria Ltd Nationale d’Operations Petrolieres de Cote d’Ivoire (NOPCI) Nigerian Agip Oil Company Ltd Saipem Contracting Nigeria Ltd Shell Nigeria Shell Petroleum Development Co of Nigeria Ltd Technip Offshore Nigeria Ltd Topline Limited Total E&P Nigeria Ltd
Poland
Singapore
Danfoss Poland Sp z o o ESAB Sp z o o Fersab Sp z o o Harris Calorific International Sp z o o Ozas Sp z o o Thoni Alutec Sp z o o Whirlpool Polska Sp z o o
Air Products Asia Applus RTD PTE Ltd BP Singapore Pte Ltd Cameron (Singapore) Pte Ltd Det Norske Veritas Industry Pte Ltd ESAB AsiaPacific Pte Ltd ESAB Singapore Pte Ltd Esso Singapore Pte Ltd ExxonMobil Singapore Pte Ltd FMC Southeast Asia Pte Ltd FMC Technologies Singapore Pte Ltd FTV Proclad (Singapore) Pte Ltd Hitachi Zosen Singapore Ltd INTECSEA Singapore JGC Singapore Pte Ltd Keppel FELS Ltd Kobe Welding (Singapore) Pte Ltd McDermott Asia Pacific Pte Ltd MODEC Management Services Pte Ltd MODEC Offshore Production Systems (Singapore) Pte Ltd Oil States Industries (Asia) Pte Ltd Proclad International Asia Pacific Pte Ltd REC Cells Pte Ltd Shell Chemical Seraya PTE Ltd Shell Eastern Petroleum (Pte) Ltd Soxal Subsea7 Singapore Pte Ltd Transocean Eastern Pte Ltd
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Portugal Air Liquide Portugal Air Liquido Electro Arco ESAB Lda SONACERGY Serviços e Construçoes Petroliferas Lda
Qatar Deutsche Babcock Al Jaber WLL Dolphin Energy Ltd Maersk Oil Qatar AS Oryx Engineering Solutions LLC Qatar Liquefied Gas Co Ltd Qatar Petroleum Qatar Shell GTL Ltd Q-Chem RAF (A) Water & Power Station Saipem - Doha
Romania Autoliv Inflator Romania Rubitech Romania SC Grup Servicii Petroliere SA TenarisSilcotub
Oman L&T MFY LLC L&T Modular Fabrication Yard LLC Petroleum Development Oman LLC Saipem SpA Oman
Pakistan BP Pakistan Exploration & Production Inc
Peru Talisman (Peru) Ltd Sucursal Peruana
Philippines Air Liquide Philippines Chevron Geothermal Philippines Holdings Inc Philipinas Shell Petroleum Corp Technoserve International Co Inc
Russia OOO ‘ESAB’
Saudi Arabia Aquilex Arabia Ltd Aramco Gulf Operations Company Ltd Babcock Borsig Power Service Arabia Ltd Eastern Petrochemical Company (SHARQ) Hitachi Plant Technologies (HPT) JGC Arabia Ltd Luberef NOV Tuboscope Vetco Saudi Arabia Ltd PEMREF SABIC Sabic Petrokemya Saipem SAL KSA Saudi Arabian Oil Co Saudi Aramco Saudi Aramco Oil Company Shaw Stone & Webster Arabia Co Ltd Technip Saudi Arabia Yanbu National Petrochemical Company
Slovakia ESAB Slovakia sro
South Africa Air Liquide (Pty) Ltd Air Products South Africa Pty Ltd ArcelorMittal South Africa Vanderbijlpark Works Arnot Power Station Chevron South Africa (Pty) Limited Drakensberg Power Station Duvha Power Station Element Six (Pty) Ltd ESKOM - Megawatt Park ESKOM Enterprises ESKOM Holdings Limited Eskom Properties Gariep Power Station Hendrina Power Station Hitachi Power Africa Joy South Africa Pty Ltd Kendal Power Station Koeberg Power Station Kriel Power Station Lethabo Power Station Majuba Power Station Matimba Power Station Matla Power Station Murray & Roberts Marine Oerlikon Electrodes (SA) (Pty) Ltd Palmiet Power Station Peaking Generation
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PetroSA (Mossel Bay) Rotek Engineering (Pty) Ltd Sasol Chemical Industries Ltd Sasol Infrachem Sasol Synfuels (Pty) Ltd Sasol Technology (Pty) Ltd Shell South Africa Energy (Pty) Ltd Tutuka Power Station Weldex SA
Spain Air Liquide Espana SA Airbus Operations SL Al Air Liquide SA Applus Norcontrol S.L.U. Boeing Research & Technology Europe SL BP Oil Espana SA BP Oil Refineria de Castellon SAU Carburos Metálicos SA ESAB Iberica SA Henkel Ibérica SA Industria de Turbo Propulsores SA INITEC Tecnologia - Plantas Industriales Lincoln Electric Spain SA Navantia SL - Cartagena Shipyard
Sweden AGA Gas AB Air Liquide Gas AB Alfa Laval AB Alfa Laval Lund AB Autoflator AB Autoliv Inc Avure Technologies AB DNV Inspection AB ECAPS (Ecological Advanced Propulsion Systems) Element Six AB ESAB AB ESAB AB, Welding Equipment ESAB International AB ESAB Sverige AB Exova AB (Sweden) Höganäs AB Linde AG, Linde Gas Division L-TEC Deutschland GmbH Oerlikon Sverige AB Permascand AB Profilgruppen Extrusion AB Profilgruppen Manufacturing AB Rolls-Royce AB Sapa AB Sapa Group Sapa Heat Transfer AB Sapa Manufaktur Sapa Profiler AB Sapa Technology SSAB Oxelosund AB SSAB Svenskt Stal SSAB Tunnplat AB Swedish Nuclear Fuel & Waste Management Co (SKB) Swedish Steel AB Swenox AB Volvo Aero Corporation Volvo Aero Support AB Volvo Articulated Haulers AB Volvo Buses
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Volvo Construction Equipment AB Volvo Construction Equipment Cabs AB Volvo Construction Equipment Components AB Volvo Construction Equipment HLD Volvo Excavators AB Volvo Lastvagnar AB Volvo Powertrain AB Volvo Technology Corporation Volvo Teknisk Utveckling AB Volvo Truck Corp Volvo Wheel Loaders AB Volvo, AB WesDyne TRC AB Westinghouse Electric Sweden AB
Switzerland Allseas Group SA CARBAGAS CBMM Technology Suisse SA ESAB AG Global Petroprojects Services AG Hydro Aluminium Extrusion SA Hydro Exploitation SA MEGGITT SA Nagra Oerlikon Schweisstechnik AG Robertson and Co SA Single Buoy Moorings Inc Offshore Group Solitaire Marine Contractors SA VAT Vakuumventile AG
Thailand Chevron Thailand Exploration & Production (CTEP) CUEL Limited CUEL Limited - Construction Yard Oil States Ind. (Thailand) Ltd Thai Yamaha Motor Co Ltd
Trinidad and Tobago BG Trinidad & Tobago BP AMOCO Trinidad & Tobago BP Trinidad and Tobago
Tunisia BG Tunisia
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Ukraine ESAB Ukraine LLC
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Vette Corp Volvo Construction Equipment North America Inc Volvo GM Heavy Trucks Westinghouse Electric Corp - Welding & Machining LLC WGIM Houston Williams Field Services
Uruguay AGA SA
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TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, UK Tel: +44 (0)1223 899000
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TWI Annual Review 2012 TWI is the business name of The Welding Institute, a company limited by guarantee The Welding Institute – Registered number 405555 England TWI – Registered number 3859442 England
Production Editor: Penny Edmundson BSc Photography: Simon Condie ARPS, LBIPP Design: Craig Carter